JP2001178580A - Chair structure such as seat or backrest and method of manufacturing the same - Google Patents

Abstract

(57) [Summary] [Problem] To reduce the number of parts and manufacture easily and at low cost. SOLUTION: In a chair structure such as a seat or a backrest provided with a cushion 3, an upholstery material 4 stretched on the cushion 3, and a structural plate made of synthetic resin for supporting the cushion 3, the cushion 3 and the upper In a state where the upholstery 4 and the synthetic resin structural plate 2 are accommodated in the injection molding die 10, the molten resin material 1
1 is injected to form a structural plate by low pressure injection molding, and at the same time as the structural plate is formed, the structural plate is integrated with the cushion 3 and the upholstery 4, so that the cushion 3 and the upper overlay 4 are integrated with the structural plate. It is made to be molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a chair structure such as a chair seat or a backrest having a structural plate, a cushion and an upholstery, and a method of manufacturing the same. More specifically, the present invention relates to a chair structure in which a cushion and an upholstery are integrated with a structural board, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, as a seat or backrest of a chair, for example, a cushion made of urethane is placed on a plywood or a core made of polypropylene and covered with an upholstery such as cloth or leather from above. Is widely used. This upper-covered fabric is made by turning its edge to the back of the core material and gently pulling it to extend the slack on the front side, and then use a fastening needle such as a tack or a U-shaped needle (stapling needle or tackle). It is fixed to the core material directly by welding or welding, or is covered by narrowing the edge using a tightening means such as a wire or a rubber string. In addition, a back cover is often attached to the back side of the core material in order to conceal the frayed or cut surface of the edge of the upper covering material and improve the appearance. A seat or backrest having such a structure requires complicated operations such as pulling an upholstery, hitting a fastening needle, and squeezing the edge with a tensioning means, resulting in high cost.

[0003] In order to manufacture a chair with a thin cushion such as a simple chair, as shown in FIG. 7, an upper covering material 100, a sheet-like cushion 101 made of urethane, a thermoplastic sheet-like core material 102 are used. A sheet molded product 103, which is formed by laminating and integrating them, is attached to a resin molded product 104 as a structural member (also serving as a back cover) and used as a seat or a backrest.

[0004] A sheet molded product 103 is provided as a laminated material in which the upholstery material 100 and the cushion 101 are integrated in advance, and the core material 102 is combined with the laminated material and heated and pressed in a mold to form a laminate. It is integrated.
On the other hand, since the sheet molded product 103 alone cannot provide sufficient structural strength as a seat or a backrest, a resin molded product (structural material) 104 formed by injection molding is prepared.
A seat or a backrest is formed integrally with this by bonding or the like. The resin molded product 104 includes the sheet molded product 10
3 and a mounting portion 109 formed of a groove that can be fitted into the pipe frame 108.
Are formed.

[0005] The resin molded article 104 and the sheet molded article 103 are interposed by, for example, interposing a fusion member 107 made of a synthetic resin member containing a metal plate or a metal powder in a fixing portion 106 and applying high-frequency electromagnetic waves thereto. It is integrated by fusing. Further, a fixing method such as an adhesive or a set screw may be selected instead of the electromagnetic fusion.

The seat and backrest manufactured in this manner are:
The mounting portion 109 is assembled to the frame 108 and fixed by screws.

[0007]

However, in the seat and backrest having the above-described structure, a sheet molded product 1 is formed by lamination molding.
03, the resin molded article 104 formed separately by injection molding must be integrated by fixing means such as electromagnetic fusion, so that there are still many manufacturing steps, Equipment is required.

In addition, the strength of the seat and the backrest is insufficient with only the sheet molded product 103 and the frame 10
Since it is difficult to obtain a structure that can be attached to the resin 8, the resin molded product 104 cannot be omitted and the number of parts cannot be reduced.

Accordingly, an object of the present invention is to provide a chair structure such as a seat or a backrest, which can be manufactured simply and at low cost by reducing the number of parts, and a method of manufacturing the same.

[0010]

In order to achieve the above object, the invention according to claim 1 comprises a cushion, an upholstery ground stretched on the cushion, and a synthetic resin structural plate supporting the cushion. In a chair structure such as a seat or a backrest provided at least, the cushion and the upholstery are integrally formed with a structural plate material formed by low-pressure injection molding.

[0011] Therefore, the cushion and the upholstery are integrally formed on the structural plate material formed by low-pressure injection molding by supporting the entire surface of the cushion with the structural plate material, so that a core material for adjusting the shape is not required. The number of parts can be reduced, and the manufacturing process of the structure can be simplified.

According to a second aspect of the present invention, there is provided a chair structure such as a seat or a backrest according to the first aspect, wherein the structural plate is formed by a low-pressure injection molding at the same time as the connecting portion attached to the support structure of the chair. Things.

Therefore, since the connecting portion is formed on the structural plate, the structure can be directly attached to the support structure of the chair. For this reason,
The structure can be attached to the support structure without using a back cover or the like that has the connection part used to attach the structure to the support structure.This reduces the number of parts and simplifies the structure manufacturing process. Can be planned.

Further, the invention described in claim 3 is the invention according to claim 1.
Alternatively, in the structure of the chair such as the seat or the backrest described in 2 above, the cushion and the upholstery are made of a laminated material that has been integrated in advance. In this case, it is possible to prevent a shift or a wrinkle from occurring between the upper lining and the cushion.

According to a fourth aspect of the present invention, there is provided a method for manufacturing a chair structure such as a seat or a backrest, wherein a cushion and an upholstery are accommodated in an injection mold of a synthetic resin structural plate. To form a structural plate by low-pressure injection molding, and at the same time as the structural plate is formed, this structural plate is integrated with the cushion and the upholstery.

[0016] Therefore, since the upper board and the cushion are integrated with the structural board at the same time as the low-pressure injection molding of the structural board, the work of attaching the cushion and the upper board to the structural board is not required, and the manufacturing is performed accordingly. The process can be simplified. Moreover, since the injection molding of the structural plate is performed by low-pressure injection, the cushion can be prevented from collapsing and the cushioning property of the structure can be ensured. Therefore, the integral molding of the structural plate with the cushion and the upholstery can be realized. it can.

According to a fifth aspect of the present invention, there is provided a method for manufacturing a chair structure such as a seat or a backrest according to the fourth aspect, wherein the structural plate is formed by simultaneously injecting the connecting portion attached to the support structure of the chair at a low pressure. It is made to be molded.

In this case, since the connecting portion is injection-molded integrally with the structural plate, there is no need to prepare and attach a separate connecting member, and the structure can be directly attached to a support-side structure of a chair such as a leg frame. Will be able to

Further, the invention according to claim 6 is based on claim 4
Alternatively, in the method for manufacturing a chair structure such as a seat or a backrest according to the item 5, the cushion and the upholstery are made of a laminated material that has been integrated in advance. Therefore, when installing the upholstery and the cushion in the low-pressure injection mold, it is possible to prevent wrinkles due to a shift between the upholstery and the cushion.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The configuration of the present invention will be described below in detail based on an example of an embodiment shown in the drawings. 1 and 2 show an embodiment in which a chair structure such as a seat or a backrest of the present invention is applied to a chair seat. The seat 1 of this chair is
The vehicle includes a cushion 3, an upholstery ground stretched on the cushion 3, and a structural plate made of a synthetic resin that supports the cushion 3. The structural plate is formed by low-pressure injection molding, and is integrally formed with the cushion 3 and the upholstery. In low-pressure injection molding, the pressure in the mold at the time of resin injection is much lower than that during normal injection molding (for example, about 20MP), and is, for example, about 5MP. Therefore, the cushion 3 is not crushed during molding. Therefore, the cushioning property of the structure can be ensured by preventing the crushing of the cushion 3 at the time of molding, so that the integral molding of the structural plate member 2 with the cushion 3 and the upholstery 4 can be realized. Since the formation of the structural plate member 2 and the integration of the upper covering material 4 and the cushion 3 can be performed simultaneously, the core member of the seat plate or the back plate and the back cover, which are conventionally separate members, are combined into one member. Thus, the number of parts constituting the structure can be reduced, and the manufacturing process of the structure can be simplified.

In the seat 1, the connecting portion 5 of the structural plate 2 attached to the chair support structure (hereinafter, also referred to as a frame) 6 is simultaneously formed by low pressure injection molding. Here, in the present embodiment, the chair to which the seat 1 is attached is a fixed-type pipe chair or a folding pipe chair in which a frame pipe as the support structure 6 is used as a support leg. For this reason, since the seat 1 can be directly attached to the frame 6 of the chair, for example, it is not necessary to use a back cover or the like having a connecting portion which has been conventionally used for attaching the seat 1 to the frame 6. Thus, the number of parts can be reduced, and the manufacturing process of the seat 1 can be simplified.

The connecting portion 5 has a pipe groove 7 capable of accommodating the frame 6 and can be attached so as to cover the frame 6. Therefore, the seat 1 can be fitted to the frame 6 with one touch. And
By forming, for example, a claw portion that enters the lower side of the frame 6 in the connecting portion 5, it is possible to prevent the connecting portion 5 from being easily detached after being attached to the frame 6. Further, by forming a bolt through-hole in the connecting portion 5 and the frame 6 and screwing it, the connection between the seat 1 and the frame 6 can be further strengthened.

Here, the seat surface 8 of the seat 1 is formed as a chair as required. Specifically, for example, as shown in FIG. 1, it can be formed into a flat shape, a shape having a recessed central portion, or a shape having a projected central portion. Further, a rib for reinforcement may be provided on the back surface of the structural plate 2.

Both the upper covering material 4 and the cushion 3 are made of a sheet material over the entire area of the seating surface 8. The edges 9 of the upper covering material 4 and the cushion 3 are embedded in the structural board 2 by insert molding. For this reason, it is possible to prevent each edge 9 from peeling off from the structural plate 2 even if the edge 9 of the upper covering material 4 is not fixed to the structural plate 2 by a tacker or the like. Moreover, at the time of low-pressure injection molding of the structural plate 2, the molten material of the structural plate 2 impregnates the surface layer of the cushion 3, so that the structural plate 2 and the cushion 3 are integrated and the cushion 3 is separated from the structural plate 2. Is prevented.

Here, by changing the thickness and material of the cushion 3 for each location, the cushioning properties can be varied depending on the portion of the seating surface 8. For example, it is possible to improve the sitting comfort by making the part of the seated person hitting the body particularly high in cushioning properties.

The upper covering material 4 and the cushion 3 are laminated in advance by bonding or welding. This makes it possible to prevent wrinkles from occurring on the upholstery 4 and also prevent peeling of the upholstery 4 from the cushion 3.

In the case of the present embodiment, the structural plate 2 is made of a thermoplastic synthetic resin such as PP, the cushion 3 is made of a polyurethane foam sheet, and the upholstery 4 is made of PP.
The seat is adopted. The structural plate material 2 is not limited to PP, and may be, for example, an ABS (acrylonitrile butadiene styrene) resin material corresponding to the strength required for a chair. Further, the structural plate member 2 is not limited to a thermoplastic synthetic resin, and may be a thermosetting synthetic resin. The cushion 3 is not limited to a polyurethane foam, but may be a polyethylene (hereinafter, referred to as PE) foam, a PP sheet, or the like. Further, the upper covering material 4 may be made of leather, cloth, or a planted PP sheet according to the appearance of the chair. Assuming that all of the structural plate material 2, cushion 3 and upper covering material 4 are made of an olefin-based material, the seat 1 removed when the chair provided with the seat 1 is discarded is melted to obtain an olefin-based material. Can be recycled. Thus, resources can be effectively used, and waste materials can be reduced.

As each material of the structural plate 2, the cushion 3, and the upholstery 4, a new olefin resin material, a recycled PP material, or the like can be used. Further, for the seat 1 having a small necessity of recycling, the structure plate 2 is not limited to using a pure olefin-based resin material, and a material obtained by mixing the main material with another material may be used. . Other materials to be mixed include, for example, recycled materials, glass fibers, talc, wood flour, reinforcing materials and the like. Thereby, the structural board 2
Rigidity can be increased.

The procedure for forming the above-described chair seat 1 will be described below.

In the method of manufacturing the seat 1, the cushion 3 and the upholstery 4 are combined with the injection molding die 10 of the structural plate 2 made of synthetic resin.
The structural plate 2 is formed by low-pressure injection molding in a state of being housed inside, and the structural plate 2 is integrated with the cushion 3 and the upholstery 4 at the same time as the structural plate 2 is formed.

More specifically, as shown in FIG. 3A, the cushion 3 and the upholstery 4 that have been laminated in advance
In the state where the mold 10 is slightly opened, the molten material 11 of the structural plate 2 is injected and insert-molded. At this time, since the mold 10 is slightly opened, the pressure of the molten material 11 can be smaller than when the mold 10 is completely closed. Thereby, the crush of the cushion 3 due to the injection of the molten material 11 can be prevented.

Then, as shown in FIG. 3B, the mold 10 is closed at a predetermined timing, and the resin is caused to flow to shape the resin. For this reason, the force with which the molten material 11 of the structural plate member 2 presses the cushion 3 at the time of mold clamping can be reduced, so that the cushion 3 can be suppressed from being crushed and the cushioning property can be secured.

Further, by opening the mold 10 after the molten material 11 is cooled and hardened, the seat 1 is taken out as an integrally molded product of the upper lining 4 and the cushion 3 and the structural plate 2. In this embodiment, since the connecting portion 5 is formed on the structural plate member 2, the connecting portion 5 is also integrally formed at the same time when the seat 1 is formed. Therefore, the manufacturing process of the seat 1 can be simplified.

The above embodiment is an example of a preferred embodiment of the present invention, but the present invention is not limited thereto, and various modifications can be made without departing from the gist of the present invention. For example, in the present embodiment, the upper lining 4 and the cushion 3
Has a laminated structure in which the upper layer 4 and the cushion 3 are separately formed.
May be inserted into the mold 10 and then subjected to insert molding. In this case, the edge 9 of the upper covering 4 is embedded in the structural board 2 so as to cover the cushion 3 by being embedded in the structural board 2, so that the upper covering 4 can be used without using a fixing means such as a tacker. 4 is prevented from being peeled off from the structural plate 2. The seat 1 can also be integrated with the upholstery 4 and the cushion 3 at the same time when the structural plate 2 is formed, so that the manufacturing process of the seat 1 can be simplified.

In the above-described embodiment, the cushion 3 is provided on the entire surface of the seat 8. However, the present invention is not limited to this, and the cushion 3 may be provided only on a part of the seat 8.

Further, in the above-described embodiment, the chair seat 1 is mounted on a pipe chair having a frame pipe as a supporting leg. However, the present invention is not limited to this. Or other types of chairs. When attaching to a folding chair having a frame structure, the seat 1 described above may be used and fixed to a frame. In addition, when it is attached to an office swivel chair, as shown in FIG. 4, the connecting portion 5 is formed in a boss shape which can be screwed to the seat receiving member. Then, a bolt is screwed into the connecting portion 5 from below the seat receiving member to fix the seat 1 to the seat receiving member. According to this,
Since the connecting portion 5 is integrally formed on the structural plate member 2, the seat 1 can be attached to the seat receiving member as it is, and the connecting portion 5 made of a separate member is not required, thereby simplifying the manufacturing process of the chair. Can be.

Further, in each of the above embodiments, the edge 9 of the upper covering material 4 and the cushion 3 is embedded in the structural plate 2 by insert molding. However, the present invention is not limited to this. For example, as shown in FIG. Groove 12 in the structural plate 2 around
May be formed so that the upper covering material 4 and the edge 9 of the cushion 3 are inserted into the groove 12 without being inserted. In this case, the upper upholstery 4 and the cushion 3 are laminated in advance to prevent the upper upholstery 4 from peeling off.

Furthermore, in the above-described embodiment, the upper base material 4 and the edge 9 of the cushion 3 are formed integrally with the structural plate material 2. However, the present invention is not limited to this. For example, as shown in FIG. The ground 4 and the edge 9 of the cushion 3 are extended so as to hang down from the peripheral edge of the structural plate material 2, and when the seat 1 is attached to the frame 6, the edge 9 is connected to the pipe groove 7 as shown in FIG. It may be folded inward and held between the frame 6 and fixed. Here, the edge 9 is fixed by the clamping force between the frame 6 and the inner surface of the pipe groove 7, but the invention is not limited to this, and the edge 9 and the pipe groove 7 are fixed by tacking or bonding. Alternatively, if the seat 1 does not have the pipe groove 7, the edge 9 may be wrapped around the back side of the peripheral edge of the structural plate material 2 and fixed by tacking or bonding. According to these, the upholstery material 4 and the cushion 3 can be stretched over the entire surface of the structural board 2.

Further, in the above-described embodiment, the case where the structure of the chair is the seat 1 is described. However, the present invention is not limited to this, and the structure plate member 2 and the cushion, such as the backrest, armrest and headrest of the chair, are not limited thereto. The present invention can be applied to other chair structures having the above-mentioned structure 3 and the upper covering material 4.

[0040]

As is apparent from the above description, according to the structure of the chair such as the seat or the backrest according to the first aspect of the present invention, the upholstery and the cushion are applied to the structural plate formed by low-pressure injection molding. Since the entire surface of the cushion is supported and integrated by the structural plate, a core material for adjusting the shape is not required, the number of parts can be reduced, and the manufacturing process of the structure can be simplified.

Further, according to the structure of the chair such as the seat or the backrest according to the second aspect, since the connecting portion is formed integrally with the structural plate, this structure can be directly attached to the chair supporting structure. It is not necessary to prepare and attach a connecting part made of a separate member unlike the conventional structure, so that the number of parts can be reduced, the number of working steps can be reduced, and the manufacturing cost can be reduced.

Further, according to the structure of the chair such as the seat or the backrest according to the third aspect, since the upholstery, the cushion and the structural plate are integrated, no wrinkles are formed on the upholstery.

On the other hand, according to the method of manufacturing a chair structure such as a seat or a backrest according to the fourth aspect, simultaneously with the low-pressure injection molding of the structural plate, the upholstery and the cushion are integrated with the structural plate. Therefore, the work of attaching the cushion and the upholstery to the structural plate material is not required, and the manufacturing process can be simplified accordingly. Moreover, since the injection molding of the structural plate material is performed at a low pressure, the cushion can be prevented from being crushed and the cushioning property of the structure can be ensured.
The integral molding of the structural plate material with the cushion and the upholstery can be realized.

Further, according to the method of manufacturing a chair structure such as a seat or a backrest according to the fifth aspect, a connecting portion for directly attaching the structure to a chair-side support structure is formed at the same time when the structural plate is formed. Therefore, it is not necessary to separately prepare a connecting member or the like and attach it to the structural plate, so that the number of manufacturing steps can be reduced correspondingly.

Further, according to the method for manufacturing a chair structure such as a seat or a backrest according to the sixth aspect, since the cushion and the upholstery are made of a laminated material that has been integrated in advance, It is possible to prevent wrinkles from occurring by preventing displacement or movement between the upholstery material and the cushion during installation at low pressure or low pressure injection molding.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional side view showing a case where a structure of a chair such as a seat or a backrest according to the present invention is applied to a seat.

FIG. 2 is a longitudinal sectional side view showing a part of a seat.

FIG. 3 is a longitudinal sectional side view showing a manufacturing procedure of the seat;
(A) is a state in which the molten material is injected while the mold is slightly opened, and (B) is a state in which the mold is clamped at a low pressure.

FIG. 4 is a longitudinal sectional side view showing a part of a seat according to another embodiment.

FIG. 5 is a longitudinal sectional side view showing a part of a seat according to still another embodiment.

FIG. 6 is a longitudinal sectional side view showing a part of a seat according to another embodiment, wherein (A) is a state before being attached to a frame, (B).
Is a state after being attached to the frame.

FIG. 7 is a longitudinal sectional side view showing a conventional seat.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Seat (structure) 2 Core material 3 Cushion 4 Upper fabric 5 Connection part 6 Chair frame (support structure)

Claims (6)

[Claims] 1. A chair structure, such as a seat or backrest, comprising at least a cushion, an upholstery ground over the cushion, and a structural plate made of synthetic resin for supporting the cushion, the cushion and the upper A chair structure such as a seat or a backrest, wherein the upholstery is integrally formed with the structural plate material formed by low-pressure injection molding. 2. The structure of a chair such as a seat or a backrest according to claim 1, wherein the connecting portion of the structural plate is attached to the support structure of the chair by low pressure injection molding. . 3. A chair structure such as a seat or a backrest according to claim 1, wherein the cushion and the upholstery are laminated materials integrated in advance. 4. A method of manufacturing a chair structure such as a seat or a backrest, wherein said structural plate is low-pressure injection-molded with a cushion and an upholstery placed in an injection mold of a synthetic resin structural plate. Wherein the structural plate is integrated with the cushion and the upholstery at the same time as the structural plate is formed. 5. The chair structure such as a seat or a backrest according to claim 4, wherein the connecting portion attached to the support structure of the chair is simultaneously low-pressure injection molded. Manufacturing method. 6. The method for manufacturing a chair structure such as a seat or a backrest according to claim 4, wherein the cushion and the upper covering material are laminated materials integrated in advance.